Multi-segmented tube sheet

ABSTRACT

A method of manufacturing a tube sheet by forming a plurality of separate thin tube sheet segments; forming multiple holes in each sheet in a predetermined pattern, each hole for accommodating a tube sheet filter tube; aligning all of the plurality of tube sheet segments so that the hole pattern of each sheet aligns with the hole pattern in all other sheets of the plurality of tube sheet segments; and securing all of the tube sheet segments together to form a unitary tube sheet. A tube sheet construction that includes a plurality of separate thin tube sheet segments, multiple holes being provided in each sheet in a predetermined pattern, each hole for accommodating a tube sheet filter tube, all of the tube sheet segments being aligning so that the hole pattern of each sheet aligns, and fasteners for securing all of the tube sheet segments together. A media layer is provided between adjacent sheet segments.

RELATED CASE

This application is a continuation-in-part (CIP) of U.S. Ser. No.14/535,596 filed on Nov. 7, 2014 which claims priority to under 35U.S.C. §119 (e) to commonly owned and co-pending U.S. Provisional PatentApplication No. 62/063,681 which was filed on Oct. 14, 2014, and whichis incorporated by reference herein in its entirety. Reference is alsomade to co-pending application Ser. No. 14/535,655 filed on Nov. 7,2014, and a co-ending continuation-in-part (CIP) application theretofiled of even date herewith and presently identified by attorney docketnumber 03414-1. All of the above identified applications areincorporated by reference herein in their entirety.

FIELD OF THE INVENTION

The present invention relates in general to tube sheets that aretypically used in such applications as filtration and heat exchange.More particularly, the present invention relates to an improvement inthe construction of a tube sheet that enhances the function of the tubesheet and enables the tube sheet to be manufactured with less expense.Even more particularly the present invention relates to an improved tubesheet construction for providing greater process control by employing anactive media layer for a tube sheet used in particular in a filtrationconstruction.

BACKGROUND OF THE INVENTION

In the field of filtration and heat exchange, there is a device commonlyused to develop separate regions; commonly referred to as a tube sheet.The tube sheet is meant to be supported in a housing or tank and is usedprimarily for the support of a plurality of filter elements that areusually in the form of filter tubes for filtration or heat exchange Byway of example refer to U.S. Pat. Nos. 3,715,033; 4,609,462 and5,128,038 which describe various filter constructions in which thefilter tubes are supported by the tube sheet essentially forming aboundary region by which filtration or even heat exchange can beaffected. The tube sheet provides a support for the tubes, but alsofunctions as a bulkhead to the media on either side of the tube sheet;effectively maintaining a discontinuity so that transformation can takeplace.

In actual operation, there are times when differential pressures onopposing sides of the tube sheet are in excess of normal operatingdifferential pressures; substantial pressures in and of themselves. Inorder to overcome the differential pressure and maintain structuralrigidity the tube sheet is typically produced of a substantialthickness, and machined to a high tolerance to accept the tubes. Oneparticular disclosure of a tube sheet is shown in the '462 patent astube sheet 32.

This tube sheet thickness solves the problem of structural rigiditywhile simultaneously serving the purpose of a bulkhead and a means tomaintain the spacing between the tubes. This comes at a cost. Themachining process which typically is by drilling or water jet cutting isa slow and costly process to produce the sufficiently rigid, hightolerance barrier required.

In a typical tube sheet construction the tube sheet may be formed of ametal material such as stainless steel and can have a thickness on theorder of ½ inch. A sheet of stainless steel is fabricated to variousdiameters; between less than one foot in diameter up to a diameter ofgreater than 5 feet in diameter, and then holes [one to 2500 or moreholes] are drilled with a conventional drill bit or water jet cutter tofacilitate insertion of the tube elements. This process is cumbersomeand very time consuming; as much as 20 hours or more to produce onesheet 5 feet in diameter.

The vast majority of tube sheets in use are fabricated in this fashion,whether it is for use in a heat exchanger, filter, for reverse osmosis,distillation, or as a condenser, evaporator, or for fuel cellapplications. An objective of the present invention is to provide amulti-segment tube sheet wherein, instead of drilling a one-piece thickplate, the tube sheet is formed in multiple segments which are thenfastened together to provide structural rigidity.

Another objective of the present invention is to provide an improvedtube sheet which eliminates the costly and time consuming steps tomanufacture as with present day tube sheets.

Still another objective of the present invention is to provide animproved tube sheet structure including a stacked assembly of thinnersheets, that when assembled together provide the structural integrity ofthe present day tube sheet but at a substantially manufacturing reducedcost.

A further objective of the present invention is to provide an improvedtube sheet structure including a stacked assembly of thinner sheets, andin which the thinner sheets are more readily processed for creatingholes therein such as by being punched on an automated press, burnedwith a laser or a plasma cutter, or formed by being printed usingadditive manufacturing technologies; ie 3D printing as but one example.

Another objective of the present invention is to provide an improvedtube sheet construction including an interstitial layer referred toherein as a media layer so that the tube sheet functions both as a tubesheet as well as a multifunctional processing device.

A further objective of the present invention is to provide an improvedtube sheet construction that provides, in addition to multiple sheetsegments, a unique intermediate layer referred to herein as a medialayer for providing any one of a number of additional functionsincluding, but not limited to, filtration, flow control, shockabsorption, magnetic characteristics, dosing, chemical or medicaltreatment, or ion exchange

SUMMARY OF THE INVENTION

To accomplish the foregoing and other objects, features and advantagesof the present invention there is provided an improved tube sheetstructure and associated method of manufacturing such a tube sheet,while solving the above mentioned problems associated with present tubesheet constructions. The present invention solves the problem ofmaintaining the high tolerance, tube spacing, and structural rigidity ofthe tube sheet. This is achieved in accordance with the presentinvention by manufacturing the tube sheet out of multiple thinner layersof sheet that are critically aligned to each other and to the tubes inthe assembly process, and then fixing this assembly together to achievethe final structural integrity and bulkhead characteristics of a tubesheet.

For the present invention the same end-use tube sheet in thisarrangement will take a fraction of the time to manufacture, dueprimarily to the substantially reduced thickness of individual sheets,if punched on an automated press, burned with a laser or a plasmacutter, or printed using additive manufacturing technologies [ie 3Dprinting as but one example] and assembled and fixed. An added featurein accordance with the present invention is that layering of the tubesheet allows interstitial placement of materials creating anon-homogeneous device that in its entirety functions both as a tubesheet as well as a multifunctional filtration device or membrane. Fixingthe thin sheets into contact serves the purpose of maintaining thebulkhead effect and the structural integrity, as well as the desiredtube spacing. One or more fasteners are used to secure all layers orsheets together as a unitary mass functioning as a tube sheet. By“fasteners” reference can be made to any one of a number of devices ortechniques by which the individual layers or sheets are securedtogether.

In accordance with one aspect of the present invention there is provideda method of manufacturing a tube sheet by forming a plurality ofseparate thin tube sheet segments; forming multiple holes in each sheetin a predetermined pattern, each hole for accommodating a tube sheetfilter tube; aligning all of the plurality of tube sheet segments sothat the hole pattern of each sheet aligns with the hole pattern in allother sheets of the plurality of tube sheet segments; and securing allof the tube sheet segments together to form a unitary tube sheet.

In still other aspects of the present invention the forming of holes isby means of punching the holes concurrently; by punching the holes on anautomated press; by burning with a laser; by means of a plasma cutter;by printing or etching using additive manufacturing technologies such as3D printing; including inserting a media layer between adjacent sheetsegments; including inserting multiple media layers between adjacentsheet segments; wherein the media layer is comprised of a filter layer;and wherein the securing of the layers is by means of at least one ofpermanently constructed as with rivets, weld, solder, braze, epoxy, orconstructed with removable fasteners such as bolts, screws, removablerivets, etc. or simply floated between some reference points tofacilitate loading of the media.

In another embodiment of the present invention there is provided a tubesheet construction that includes a plurality of separate thin tube sheetsegments, multiple holes being provided in each sheet in a predeterminedpattern, each hole for accommodating a tube sheet filter tube, all ofthe tube sheet segments being aligning so that the hole pattern of eachsheet aligns with the hole pattern in all other sheets of the pluralityof tube sheet segments, and fasteners for securing all of the tube sheetsegments together.

In a further aspect of the present invention including at least onemedia sheet interposed between adjacent sheet segments; including morethan one media sheet disposed respectively between adjacent sheetsegments; wherein the media layer comprises a filtration layer clampedbetween adjacent sheet segments; wherein each sheet segment is planar inshape having a thickness that is an order of magnitude less than adiameter of the tube sheet segment; including means for forming eachhole including one of a punch device, a laser cutter, a plasma cutter,and etching device; wherein the securing of the layers is by means of atleast one of permanently constructed as with rivets, weld, solder,braze, epoxy, or constructed with removable fasteners such as bolts,screws, removable rivets, etc. or simply floated between some referencepoints to facilitate loading of the media; including a flange at one endof each filter tube for retaining each filter tube within the tubesheet; wherein the flange is disposed between adjacent sheet segments;and including a cover disposed over all of the sheet segments; andwherein the media layer is formed of one of a layer for filtration, flowcontrol, shock absorption, magnetic characteristics, dosing, chemical ormedical treatment, or ion exchange

In another version of the present invention there is provided a tubesheet construction that is comprised of a plurality of separate planartube sheet segments, multiple holes being provided in each planar tubesheet segment in a predetermined pattern, each hole for accommodating anelongated tubular element, an active planar layer disposed parallel withthe plurality of separate tube sheet segments, and fasteners forsecuring all of the planar tube sheet segments and the active planarlayer together and arranged so that all planar tube sheet segments andsaid active planar layer are maintained in intimate contact so as toform a solid tube sheet structure. The active layer comprises a UV lightemanating layer that doses any fluid flow through the tube sheetconstruction with UV light emanating from the UV light emanating layerso as to disrupt or annihilate any living matter.

In still another version of the present invention there is provided atube sheet construction that includes a tube sheet and a plurality ofelongated tubular elements supported by the tube sheet, said tube sheetcomprised of a plurality of separate planar tube sheet segments,multiple holes being provided in each planar tube sheet segment in apredetermined pattern, each hole for accommodating one of the pluralityof elongated tubular elements, all of the tube sheet segments beingaligning so that the hole pattern of each segment aligns with the holepattern in all other segments. In this version the elongated tubularelement has a flanged top end and a contiguous tubular shaft with theflanged top end having a diameter greater than a diameter of the tubularshaft. A securing piece may be used and constructed and arranged aboutthe tubular shaft of the elongated tubular element and spaced below theflanged top end of the elongated tubular element. The securing piece isfor engagement with the tubular shaft to provide a compressive forceagainst the tube sheet segments that are disposed between the flangedtop end of the elongated tubular element and the securing piece.

In still a further version of the present invention there is provided atube sheet construction that is comprised of a plurality of separateplanar tube sheet segments, multiple holes being provided in each planartube sheet segment in a predetermined pattern, each hole foraccommodating an elongated tubular element, a passive planar layerdisposed parallel with the plurality of separate tube sheet segments,and fasteners for securing all of the planar tube sheet segments and thepassive planar layer together and arranged so that all planar tube sheetsegments and said passive planar layer are maintained in intimatecontact. The passive layer is formed as a layer impregnated with one ofa medical and chemical substance that is released over time. Otheraspects include wherein the medical or chemical substance is releasedover time based on temperature; the tube sheet construction functions asa heat exchanger; the tube sheet construction is in the form of a bloodwarming device; the medical or chemical substance is released over timebased on fluid flow.

BRIEF DESCRIPTION OF THE DRAWINGS

It should be understood that the drawings are provided for the purposeof illustration only and are not intended to define the limits of thedisclosure. In the drawings depicting the present invention, alldimensions are to scale. The foregoing and other objects and advantagesof the embodiments described herein will become apparent with referenceto the following detailed description when taken in conjunction with theaccompanying drawings in which:

FIG. 1 is a perspective view of a first embodiment of the presentinvention;

FIG. 1A is a cross-sectional view through the tube sheet of FIG. 1 astaken along line 1A-1A;

FIG. 2 is a perspective view of a second embodiment of the presentinvention;

FIG. 2A is a cross-sectional view through the tube sheet of FIG. 2 astaken along line 2A-2A;

FIG. 3 is a perspective view of a third embodiment of the presentinvention;

FIG. 3A is a cross-sectional view through the tube sheet of FIG. 3 astaken along line 3A-3A;

FIG. 4 is a perspective view of a fourth embodiment of the presentinvention;

FIG. 4A is a cross-sectional view through the tube sheet of FIG. 4 astaken along line 4A-4A;

FIG. 5 is a schematic diagram showing the tube sheet as applied to afilter tank;

FIG. 6 is a cross-sectional view like that depicted in FIG. 3A where themedia layer is a passive layer in the form of a nanotubular structurewithin a platinum amalgam;

FIG. 7 is a cross-sectional view through an alternate embodiment of atube sheet;

FIG. 8 is a fragmentary cross-sectional view showing another embodimentof the present invention including a securing piece associated with thefilter tube;

FIG. 9 is an enlarged cross-sectional view showing the construction atone filter tube and employing a securing nut;

FIG. 10 an enlarged cross-sectional view showing the construction at onefilter tube and employing a push nut;

FIG. 10A is a fragmentary perspective view illustrating the push nutdisposed on a filter tube;

FIG. 11 is a fragmentary cross-sectional view of another embodiment ofthe present invention employing the securing piece; and

FIG. 12 is a fragmentary cross-sectional view showing the use of thesecuring piece associated with each filter tube and a sensor.

DETAILED DESCRIPTION

As mentioned before, in accordance with the present invention the tubesheet is constructed out of multiple thinner layers of sheet materialthat are aligned to each other and to the tubes in the assembly process,and then fixing this assembly together to achieve the final structuralintegrity and bulkhead characteristics of a tube sheet. In the drawingsseveral different versions of the invention are set forth such as inFIGS. 1-4. FIG. 5 is an illustration of the application of theprinciples of the present invention to a filtration structure, althoughit is contemplated that the principles of the present invention can beapplied to other systems and devices such as for heat exchange FIG. 6shows one alternate embodiment in the form of a nanotubular structure.In connection with the various embodiments of the tube sheetconstruction shown herein reference is now also made to co-pendingapplication Ser. No. 14/535,655, (attorney docket number 03414) which ishereby incorporated by reference herein in its entirety, andillustrating the application of the principles of the present inventionto a heat exchanger.

In accordance with one aspect of the present invention there is provideda method of manufacturing a tube sheet by forming a plurality ofseparate thin tube sheet segments such as shown in FIG. 1 as layers orsheets 1-6. The next step is forming multiple holes in each sheet in apredetermined pattern such as illustrated at 11 in the drawings herein.Each hole 11 is for accommodating a tube sheet tube 8. A next step isaligning all of the plurality of tube sheet segments 1-6 so that thehole pattern of each sheet aligns with the hole pattern in all othersheets of the plurality of tube sheet segments and securing all of thetube sheet segments together to form a unitary tube sheet such as withthe use of fasteners 12 in the embodiment of FIG. 1. Most likely severalfasteners would be employed throughout the tube sheet in order toprovide a secured unitary structure. All fasteners or other securingmeans is meant to hold all sheets or layers together.

Additionally, one variation of the present invention allows forstacking, not just the tube sheet layers, but in effect the stacking andretention of other filtration or conversion media between the segmentedtube sheet layers. This extra media sheet is illustrated in the drawingsherein. For instance, progressively finer filter media between thesheets will facilitate backwashing to regenerate the sheets.Alternatively, reactive substances may be layered in the stacks suchthat contact with this substance alters the media passing through thatsection. Another possibility that this invention facilitates over theprior art relates to conductive versus insulative materials and theembedding of electronic, magnetic, plasma, unlimited combinations ofmetals and non-metals, the difference which manifest themselves as asubcomponent of the greater assembly which is that of a segmented tubesheet.

It is noted that the “media” layer, identified herein by a layer 10 inthe drawings and also referred to as an interstitial layer, can take ona multitude of forms. This layer is referred to herein in thisparticular application as being either a “passive layer” or an “active”layer. In either case this layer describes an intermediate layer that isessentially a subcomponent of the whole assembly (tube sheet) butworking in concert with the whole assembly to provide uniquecharacteristics not possible with existing tube sheet constructions. A“passive” layer may be considered as one in which, by the selection ofdifferent materials for that layer, one can provide different effectsupon the fluid flow through the system, while at the same time not beingconsidered as providing any active stimulus or response. An “active”layer, on the other hand, may be considered as one in which either anexternal stimulus is applied to the layer or a response is elicited fromthe layer. Examples of a “passive” layer are where the media layerprovides filtration, flow control, shock absorption, magneticcharacteristics, dosing, chemical or medical treatment, or ion exchange.Examples of an “active” layer are where the media layer is used to sensea parameter within the tube sheet such as pressure or temperature(response) or where the media layer is externally excited such as byapplying a magnetic field to the layer (stimulus). Other examples areset forth herein.

For filtration and heat exchange applications it is common to constructthe tube sheet of a metal material such as stainless steel. However, inaccordance with the present invention the tube sheet, or certain layersthereof, can also be formed of an insulative or non-metal material suchas a glass reinforced plastic material. Also, alternating conductive andnon-conductive materials for the various layers can be provided,examples of which are set forth later.

For filtration purposes the media layers (reference number 10 in thedrawings) can take the form of a single or multiple layup of filterpaper or screen material of a woven, matted, or other construction.Alternatively, the media layer can take the form of a bonded nanotubularor amalgam structure with platinum acting as a catalytic agentsuppressing H2O conversion to H2 as but one example; while continuing tofunction as a tube sheet as the superstructure of the device (see FIG.6). This layer serves as the site of catalysis in a redox reactionproviding both expanded surface area and the requisite catalyst, in thiscase platinum, to enable a reaction that occurs faster and with lessenergy. Since in the reaction, catalysts regenerate, only a small amountis generally required.

Again, one can envision a circumstance where, in this now discontinuoustube sheet device, the interstitial layer is attached to electricalcontacts and the interstitial layer is itself a device that countspassing target molecules. Another envisioned energized interstitiallayer senses any number of differences across the breadth of the device;for example, differential pressure where a single heat exchangerutilizes a plurality of tube sheets. Yet another envisioned interstitiallayer within one or more layers of the tube sheet could be measuring thetemperature differential across the tube sheet and feeding back in realtime to enhance computational fluid dynamics software to form animproved open or closed-loop arrangement that enables a new breed ofhighly interactive tube sheets.

FIGS. 1 and 1A shows a particular version of a multi-segmented tubesheet, where n=2 is the minimum number of sheets and there is no upperlimit; and the minimum tube count n=1 and there is no upper limit. Inthis particular embodiment the multi-segmented tube sheet is shown withsix sheets identified as sheets 1 through 6 arranged such that the tubes8 (themselves at times filtration elements, other times not) areinstalled. Each tube 8 may be of a type as shown in, for example, U.S.Pat. No. 3,715,033 and in which the filtration occurs through thesidewall of the tube and exits at one end of the tube 8. FIG. 5 isincluded as an example of the application of the principles of thepresent invention to a filtration apparatus. In the example provided inFIG. 5 herein the bottom of each tube is blocked so that the only exitfrom the tube is at a top end thereof into the upper effluentcompartment 36.

In addition, in FIGS. 1 and 1A there is shown a single media sheet orlayer 10 disposed just below the top sheet 1. In this particularconstruction the layer 10 is shown thicker than the other sheets 1-6 andis formed of a filtration material. In this particular embodiment thereis provided a flanged surface 9 that is disposed on the outer face ofthe second sheet 2. The first sheet 1 in this case acts as a hold downto the tubular elements 8 and all other sheets including the additionallayer of media 10 that may act as a filtration barrier or a conversionmedium to the process media as it passes from the unprocessed side tothe processed side of the apparatus (see FIG. 5 as an example), andwhich may or may not be installed at this location depending on thedesired action on the media as it transitions from the primary to thesecondary side of the tube sheet. The tube sheet stack in the assembledform may be permanently constructed as with rivets, weld, solder, braze,epoxy, etc. (see fasteners 12) or constructed with removable fastenerssuch as bolts, screws, removable rivets, etc. or simply floated betweensome reference points to facilitate loading of the media whilesimultaneously serving the purpose of a traditional tube sheet actingsimply as a bulkhead and the demarcation location between the primaryand secondary sides of the tube sheet.

FIGS. 1 and 1A also show a myriad of holes at 11 that are considered asextending through the entire tube sheet segments. Although the retentionof each tube 8 is shown in FIG. 1A is at a location of the sheet 2, itis understood that the filter tube 8 may be secured at other locationswithin the tube sheet, such as described in other embodiments disclosedherein. Also shown is a cover 13 that preferably seals the top of theassembly. All fasteners 12 are secured through the cover 13, as shown.The media layer or layers 10 are not meant to have holes therethrough aseach is to function as a filter media of some type, or as other types asmentioned herein. Thus, for example, in FIG. 1A the layer 10 iscontinuous. Also, although each flange is illustrated as recessed in oneof the segments, in an embodiment as in FIG. 1, the flange can bepositioned resting directly on the top of the surface of segment 2, asthe material of layer 10 is usually deflectable. The same also appliesto the embodiment shown in FIGS. 3 and 3A. In this embodiment, as wellas in other embodiments described herein, the fasteners are arranged sothat all separate layers are held in intimate contact with an adjacentlayer so as to maintain a solid tube sheet structure without any gapsbetween layers. This intimate contact also applies to contact with anymedia layer that is used.

FIGS. 2 and 2A shows a second version of a multi-segmented tube sheet,where n=2 is the minimum number of sheets and there is no upper limit;and the minimum tube count n=1 and there is no upper limit. In thisparticular embodiment the multi-segmented tube sheet is shown with sixsheets identified as sheets 1 through 6 arranged such that the tubes 8(themselves at times filtration elements, other times not) areinstalled. In addition there is shown a single media sheet or layer 10disposed just below the top sheet 1. Layer 10 is preferably uniform inconstruction. In this particular embodiment there is provided a flangedsurface 9 that is disposed on the outer face of the fifth sheet 5. Thefirst sheet 1 in this case acts as a hold down to the tubular elements 8and all other sheets including the additional layer of media 10 that mayact as a filtration barrier or a conversion medium to the process mediaas it passes from the unprocessed side to the processed side, and whichmay or may not be installed at this location depending on the desiredaction on the media as it transitions from the primary to the secondaryside of the tube sheet. The tube sheet stack in the assembled form maybe permanently constructed as with rivets, weld, solder, braze, epoxy,etc. (see fasteners 12) or constructed with removable fasteners such asbolts, screws, removable rivets, etc. or simply floated between somereference points to facilitate loading of the media while simultaneouslyserving the purpose of a traditional tube sheet acting simply as abulkhead and the demarcation location between the primary and secondarysides of the tube sheet.

FIGS. 3 and 3A shows a third version of a multi-segmented tube sheet,where n=2 is the minimum number of sheets and there is no upper limit;and the minimum tube count n=1 and there is no upper limit. In thisparticular embodiment the multi-segmented tube sheet is shown with onlytwo main sheets identified as sheets 1 and 2 arranged such that thetubes 8 (themselves at times filtration elements, other times not) areinstalled. In addition there is shown a single media sheet or layer 10disposed just below the top sheet 1. In this particular embodiment thereis provided a flanged surface 9 that is disposed essentially between thetwo sheets 1 and 2. The first sheet 1 in this case acts as a hold downto the tubular elements 8 and all other sheets including the additionallayer of media 10 that may act as a filtration barrier or a conversionmedium to the process media as it passes from the unprocessed side tothe processed side, and which may or may not be installed at thislocation depending on the desired action on the media as it transitionsfrom the primary to the secondary side of the tube sheet. The tube sheetstack in the assembled form may be permanently constructed as withrivets, weld, solder, braze, epoxy, etc. (see fasteners 12) orconstructed with removable fasteners such as bolts, screws, removablerivets, etc. or simply floated between some reference points tofacilitate loading of the media while simultaneously serving the purposeof a traditional tube sheet acting simply as a bulkhead and thedemarcation location between the primary and secondary sides of the tubesheet.

FIGS. 4 and 4A shows a fourth version of a multi-segmented tube sheet,where n=2 is the minimum number of sheets and there is no upper limit;and the minimum tube count n=1 and there is no upper limit. In thisparticular embodiment the multi-segmented tube sheet is shown with sixsheets identified as sheets 1 through 5 arranged such that the tubes 8(themselves at times filtration elements, other times not) areinstalled. In addition there are shown multiple media sheets 10, 14, 16and 18 disposed between adjacent sheets. In this embodiment a flangedsurface may be provided at any of the main sheets 1 through 5 preferablybelow sheet 1. Refer to FIG. 4A for examples showing different locationsof the tube flange 9. Again, the first sheet 1 in this case may act as ahold down to the tubular elements 8 and all other sheets including theadditional layer of media sheets. These media sheets may act as afiltration barrier or a conversion medium to the process media as itpasses from the unprocessed side to the processed side, and which may ormay not be installed at this location depending on the desired action onthe media as it transitions from the primary to the secondary side ofthe tube sheet. The multiple media sheets may provide progressivelyfiner filter media along the tube sheet between primary and secondarysides. The tube sheet stack in the assembled form may be permanentlyconstructed as with rivets, weld, solder, braze, epoxy, etc. (seefasteners 12) or constructed with removable fasteners such as bolts,screws, removable rivets, etc. or simply floated between some referencepoints to facilitate loading of the media while simultaneously servingthe purpose of a traditional tube sheet acting simply as a bulkhead andthe demarcation location between the primary and secondary sides of thetube sheet.

Referring now to FIG. 5, a typical tube sheet filter apparatus is shownof the general type to which the present invention is directed toimprove upon by the incorporation of the improved tube sheet of thepresent invention. The filter apparatus is designated generally by thereference numeral 20 and includes a filter tank 22, which is typicallyof generally vertical cylindrical configuration. Filter tank 22 isconfigured with an upper section 24 that may have a closed off upperhead portion and an open ended lower portion, and a lower section 28that may have an open ended upper portion in facing alignment with theupper section of the tank and an oval shaped lower portion. Therespective upper and lower sections 24 and 28 may be respectivelyprovided with annular flanges (not shown) extending outwardly adjacentthe open ends thereof. Such flanges are typically provided with alignedopenings formed therein for receipt of fastening means 12 (see FIG. 4).

FIG. 5 also illustrates a substantially horizontal plate or tube sheetindicated generally at 32 and positioned within the filter tank 22 suchthat the outer edges thereof are received and retained in place betweenflanges through a generally horizontal plane therebetween. Tube sheet 32which is formed with openings 34 (analogous to holes 11) extendingtherethrough, divides the filter tank 22 into an upper effluentcompartment 36 and a lower influent compartment 38. The tube sheet 32shown in FIG. 5 may be considered to be the same as any one of the tubesheets previously described in FIGS. 1-4 herein.

In FIG. 5 a plurality of filter elements or filter tubes 8 are supportedfrom the tube sheet 32 and extend downwardly into the influentcompartment 38. These filter elements are typically of the stainlessmesh or wire wound type, an example of which is disclosed in U.S. Pat.No. 3,779,386. The lower ends of the filter elements 8 are preferablyblocked off by some suitable means. In the embodiments illustratedherein only a limited number of tubes are shown, but in a typicalinstallation up to hundreds of tubes are supported from a tube sheet orbetween spaced apart respective tube sheets. Also, the tube sheet may besupported horizontally, vertically or in another orientation.

An effluent conduit 48 extends outwardly from the upper section 24 offilter tank 22 in fluid communication with the interior of effluentcompartment 36 for withdrawing the treated liquid therefrom. An influentconduit 50 extends outwardly from the lower portion of section 28 influid communication with influent compartment 38. A drain fitting (notshown) may extend from the lowermost end of lower section 28 throughwhich the filter tank 12 may be drained. In another embodiment of thepresent invention the effluent and influent ports may be at the sameside of the tank structure such as in a structure like that shown inU.S. Pat. No. 5,128,038.

The brief description of the operation of filter apparatus 20 whichhereinbelow follows is for the purpose of setting forth the generalnature of such operation and is not intended to be a detailed disclosureof such operation. In operation, the outer surfaces of the filterelements 8 are typically precoated with a precoat layer of particles,such as finely divided ion exchange resin particles, by passing a slurryof such particles into and through influent compartment 38 such that theparticles attach to and form a precoat layer on the outer surface of thefilter elements. During the service cycle, untreated liquid is directedthrough influent conduit 50 into influent compartment 38. The pressureof the incoming untreated liquid forces it through the precoat layer,the filter elements 8, and the effluent compartment 36 into the effluentconduit 48. As the untreated liquid passes through the precoat layer, anion exchange reaction takes place to remove dissolved impurities fromthe liquid. In addition, undissolved impurities are removed from theuntreated liquid by virtue of the liquid passing through the precoatlayer of finely divided resin particles and filter elements 8. A filtercake, consisting of undissolved impurities, builds up within and on theprecoat layer as the service cycle continues. As is well known in theart, the precoat layer may contain various combinations of reactivematerials, such as ion exchange resins, activated carbon etc., andnon-reactive materials.

Eventually, the precoat layer will become exhausted and must bethoroughly removed and discarded. At such time, the service cycle isstopped and it is necessary to clean the filter elements 8, by removingthe filter cake and the precoat layer therefrom during a backwash cycle,before the filter elements 8 are once again precoated and returned toservice. During the backwash cycle, the liquid in the filter tank 22 isdrained down and the void space thereabove is pressurized through theaddition of pressurized gas into filter tank 12. The drain conduit isthen opened and the backwash liquid in the filter tank is rapidlydrained with the assistance of the pressurized gas therein to dislodgeand remove the filter cake and precoat layer from the filter tank.

Referring now to FIG. 6, which is essentially a like embodiment to thatshown in FIG. 3A where layer 10′ is a media layer in the form of ananotubular structure within a platinum amalgam, within which, an ionexchange takes place as the fluid passes through this layer, whilepassing through the tube sheet structure. The advantage of processingthis step of an ion exchange within the tube sheet structure is thatthere is a defined segmentation of the fluid flow by the tube sheetstructure, where n=1 minimum openings with no upper limit, andtherefore, 1/n fluid flow will be treated by 1/n surface area exposed tothis flow due to the interstitial placement of the nanotubularstructure. This layer serves as the site of catalysis in a redoxreaction providing both expanded surface area and the requisitecatalyst, in this case platinum, to enable a reaction that occurs fasterand with less energy. Since in the reaction, catalysts regenerate, onlya small amount is generally required.

One further embodiment is where all layers are considered as metalliclayers. For example, and with reference to the embodiment shown in FIGS.2 and 2A, the layers 1-6 can be formed of copper sheets with aninterstitial layer 10 between those sheets of a woven screen or sinteredparticles, also of copper, that performs some filtration or acts as anorifice or a shock absorbing barrier. In this embodiment, all of thesheets may be a copper alloy.

A further embodiment that is contemplated provides the media layer asone that can control the flow level through the tube sheet by means ofspecific restrictions imposed by this layer. Refer to FIG. 7 herein. Forexample, the media layer 10 may be solid in configuration but providedwith one or more restricting orifices 19 through the surface thereof tocontrol flow rate. The size (diameter) of each orifice 19, as well asthe number of orifices determines the flow rate through the tube sheet.Such a media layer thus functions as a throttling mechanism within thetube sheet itself so as to modulate the output flow given some inputcondition such as flow and/or pressure. A media layer with one or moreorifices 19 can also function for filtration through the non-orificelocations. Thus, any one media layer may be considered as havingmultiple functions. In FIG. 7 the orifices 19 are shown as aligned withthe holes 11, however, in other embodiments the orifices may not be soaligned. If the layer 10 is somewhat porous then orifices can beprovided at many different locations in layer 10.

Another embodiment for the media layer relates to the ability to providea magnetic characteristic. In other words the concept is to constructlayer 10, such as in FIGS. 2 and 2A (or in other embodiments shownherein) from a permanent magnet or forming it from a material that couldbe imbued with magnetic properties. A magnetic circuit could be coupledto the layer 10 to provide a magnetism effect to the layer. This createsthe ability to filter out magnetic particulates as they flow through thetube sheet whether using an external excitation or using a permanentmagnet arrangement. For external excitation reference may be made toco-pending application Ser. No. 14/535,655 (attorney docket number03414) in the embodiment shown in FIG. 6 therein where an externalstimulus device is used to impart a characteristic to the media layersuch as a magnetic property. Thus, in one embodiment, the media layer 10can be constructed of a permanent magnetic material.

In this case, in the embodiment of FIGS. 2 and 2A, the layers 1 and 2can be constructed of a non-magnetic material so as not to magnify thestrength of the magnetic layer 10. Alternatively, the layers 1 and/or 2may be constructed of a material that exhibits magnetic susceptibility,such as those with ferromagnetic (e.g. iron), ferrimagnetic (e.g.magnetite), or antiferromagnetic (e.g. iron manganese, nickel oxide)qualities and, in the case of antiferromagnetic, organic molecules (e.g.5-dehydro-m-xylene).

Still another embodiment contemplates providing a passive layer as adosing layer. Referring, for example, to FIGS. 2 and 2A, the layer 10may be an interstitial sheet that has been impregnated with a medicineor a chemical that releases over time or when the temperature becomeselevated. This concept may be embodied in a device such as in atransfusion machine or where a patient with hypothermia is being treatedand one prefers a compact device that can readily release medication assoon as, for example, the patient's blood temperature raises enough.This is thus in the form of a portable multi-purpose rescue device towarm blood as in a triage on the side of a mountain when rescuingavalanche victims. Moreover, in concert with the application of amedicine or chemical, the medial layer can also be constructed using theaforementioned orifice plate to modulate flow. There is thus provided atreated layer now placed within the tube sheet itself and that providesa device that will modulate the output (medicine or chemical) given someinput condition such as flow and temperature. Again, this is an exampleof a multiple function of the media layer.

In still another embodiment for practicing the present invention thereis provided an active layer that functions as a UV light delivery zone.In this regard refer to a further version of a tube sheet as illustratedin FIG.7 herein. In this version layer 4, or other layers, may be anatural or synthetic quartz or engineered glass product that selectivelytransmits in the UV spectrum. The UV dose is delivered to thisinterstitial location via some number, where n=1 with no upper limit offiber-optic tubes 8 into the zone between layers 3 and 5, in other wordsinto layer 4. As flow passes through the tube sheet, it passes throughthe intersticies of layers 3 to 5. The flow passing will be dosed withUV light emanating from layer 4, and any living matter will have its DNAdisrupted or possibly annihilated in an example of this embodiment thatmay be part of a sanitation device. In FIG. 7 there is provided fiberoptic elements or tubes 8 a, 8 b. The layer 3 reflects into layer 4 butonly at the tubes 8 a, 8 b. At the location of the tubes aligned holesin other layers are optional.

An alternate embodiment of the present invention is now illustrated inFIGS. 8-12. FIG. 8 is a fragmentary cross-sectional view showing anotherembodiment of the present invention including a securing pieceassociated with the filter tube. FIG. 9 is an enlarged cross-sectionalview showing the construction at one filter tube and employing asecuring nut. FIG. 10 an enlarged cross-sectional view showing theconstruction at one filter tube and employing a push nut. FIG. 10A is afragmentary perspective view illustrating the push nut disposed on afilter tube. FIG. 11 is a fragmentary cross-sectional view of anotherembodiment of the present invention employing the securing piece. FIG.12 is a fragmentary cross-sectional view showing the use of the securingpiece associated with each filter tube and a sensor. The embodimentsdescribed in FIGS. 8-12 represent a further improvement to the tubesheet construction. This primarily involves use of a securing piece thatis constructed and arranged to be disposed about the tubular element orfilter tube and functions, in concert with, the flanged end of theelongated tubular element to provide a compressive force against thetube sheet segments that are disposed between the flanged top end andthe securing piece. This construction may be used in a tube sheetconstruction such as illustrated in the fragmentary cross-sectional viewof FIG. 8. In this particular embodiment the tube sheet construction isshown as including a media layer 10, although, the principles of thepresent invention may also be used in a tube sheet construction wherethere is no media layer provided.

The fragmentary cross-sectional view of FIG. 8 illustrates the flangedend at 9. This may be constructed of a grommet that is crimped about anend of the elongated hollow tubular element 8. In other embodiments ofthe present invention, this flanged member 9 may also be crimped aboutother locations along the elongated tubular element 8. FIG. 8 alsoillustrates a securing piece in the form of a nut 75 that is threadedlyengaged with the element 8. In this regard, refer to the somewhat moredetailed fragmentary cross-sectional view of FIG. 9 illustrating the nutat 75 engaged with the elongated tubular shaft 8 which has externalthreads 79. Reference may also now be made to the fragmentarycross-sectional view of FIG. 10 to show a different embodiment of thesecuring piece. This is illustrated as in the form of a push nut 76.Refer also to the fragmentary perspective view of FIG. 10A that showsfurther details of the push nut 76. The push nut 76 functions so that itcan be forced onto the shaft of the filter tube but is constructed sothat it is locked in place once pushed on and not easily disengaged fromthe filter tube 8. In FIG. 10 the filter tube 8 is shown as having asmooth outer surface. However in another embodiment of the presentinvention, it may be provided with small circular indentation rings thatassist in the positioning and engagement of the push nut 76 with thefilter tube 8.

Reference is now made to FIG. 11 which is a further fragmentarycross-sectional view showing multiple tubular elements 8 with a grommetor flanged end illustrated at 9 and with a securing piece in the form ofa nut 75 under the layer 6. The flanged end 9 is disposed above the toplayer 1 of the multiple tube sheet segments. The nut 75 is disposedunder the bottommost layer 6 of the plurality separate planar tube sheetsegments. By tightening the nut 75, there is a compressive force betweenthe nut 75 and the flange 9 providing a compression of the tube sheetsegments therebetween. Even though a cover is provided with additionalfasteners 12, the tube sheet segments may be relatively large indiameter and by providing the securing pieces as described herein, thereis additional compression and additional tension on the tube sheetsegments at virtually every location of the filter tubes. Although asecuring piece is illustrated at each of the tubes 8 in FIG. 11, it isalso possible to provide a securing piece at only predetermined ones ofthe elongated filter tubes 8. The use of securing pieces can be arrangedto provide a series of securing pieces spread throughout the tube sheetconstruction, each associated with a filter tube as illustrated, so thatthere are several locations where additional compression is applied.Also, the flanged end 9 is provided so that it engages firmly with a topsurface of the engaged tube sheet segment by virtue of the hole in thesegment being smaller than the diameter of the flanged end, leaving anannular engagement surface of the flanged end directly against the tubesheet segment surface; usually the upper surface thereof.

One particular advantage of the embodiment illustrated in FIG. 10 withthe push nut is that it makes the entire structure more tamper proof ortamper resistant. As also previously indicated, this combination of theflanged end and the securing piece introduces another level of tensionfor the securing of the tubes to the sheet segments.

Reference is now made to the fragmentary cross-sectional view of FIG. 12which shows the principles of the flanged end and securing piece appliedto a simplified tube sheet construction including layers 60, 62 and 64.In this embodiment there is also provided on each of the filter tubes 8,a flanged end at 9 and a securing piece at 75. In this particularembodiment there may also be provided an O-ring 78 between each of thesecuring nuts 75 and the layer 74. This O-ring 78 can provide additionalsealing between each filter tube and the tube sheet construction. Inaddition, FIG. 12 also illustrates a sensor 77. Multiples sensors may beprovided in the layer 60 although only one sensor 77 is shown in FIG.12. This may be a temperature or pressure sensor or virtually any othertype of sensor such as for flow control. In addition, as illustrated indotted outline in FIG. 11, sensors 77 may also be provided in differentlayers of the tube sheet construction. In FIG.12, the sensor 77 isillustrated in a media layer 60. In FIG. 11 the two sensors 77 shown indotted outline are in respective planar tube sheet segments 1 and 6.byplacing sensors at different locations within the tube sheetconstruction different parameters can be sensed such as differentpressures or temperatures across the tube sheet construction.

Having now described a limited number of embodiments of the presentinvention, it should now be apparent to those skilled in the art thatnumerous other embodiments and modifications thereof are contemplated asfalling within the scope of the present invention, as defined by theappended claims.

What is claimed is: 1-8. (canceled)
 9. The tube sheet construction ofclaim 18 including a securing piece constructed and arranged about thetubular shaft of the elongated tubular element and spaced below theflanged top end of the elongated tubular element, said securing piecefor engagement with the tubular shaft to provide a compressive forceagainst the tube sheet segments that are disposed between the flangedtop end of the elongated tubular element and the securing piece.
 10. Thetube sheet construction of claim 9 wherein the securing piece iscomprised of a threaded nut.
 11. The tube sheet construction of claim 10wherein the threaded nut abuts a lowermost planar tube sheet segment.12. The tube sheet construction of claim 9 wherein the securing piece iscomprised of a push nut.
 13. The tube sheet construction of claim 9wherein the securing piece is disposed under a lowermost planar tubesheet segment.
 14. (canceled)
 15. (canceled)
 16. The tube sheetconstruction of claim 18 wherein the flanged top end of the elongatedtubular element is recessed in one of the adjacently disposed tube sheetsegments.
 17. The tube sheet construction of claim 18 wherein the flangetop end of the elongated tubular element is positioned resting directlyon a top surface of one of the adjacently disposed tube sheet segments.18. A tube sheet construction that includes a tube sheet and a pluralityof elongated tubular elements supported by the tube sheet, said tubesheet comprised of a plurality of separate planar tube sheet segments,multiple holes being provided in each planar tube sheet segment in apredetermined pattern, each hole for accommodating one of the pluralityof elongated tubular elements, all of the tube sheet segments beingaligning so that the hole pattern of each segment aligns with the holepattern in all other segments, each said elongated tubular elementhaving a flanged top end and a contiguous tubular shaft with the flangedtop end having a diameter greater than a diameter of the tubular shaft,wherein the flanged top end of a first elongated tubular element isdisposed between a first pair of adjacently disposed tube sheetsegments, and the flanged top end of a second elongated tubular elementis disposed between a second pair of adjacently disposed tube sheetsegments that is different than the first pair of adjacently disposedtube sheet segments. 19-23. (canceled)
 24. The tube sheet constructionof claim 18 wherein one of the tube sheet segments of the first pair oftube sheet segments is the same as one of the tube sheet segments of thesecond pair of tube sheet segments.
 25. The tube sheet construction ofclaim 18 wherein one of the tube sheet segments of the first pair oftube sheet segments is the different than one of the tube sheet segmentsof the second pair of tube sheet segments.
 26. The tube sheetconstruction of claim 18 wherein both of the tube sheet segments of thefirst pair of tube sheet segments is different than both of the tubesheet segments of the second pair of tube sheet segments.
 27. The tubesheet construction of claim 18 wherein one of the tube sheet segments ofthe first pair of tube sheet segments is constructed of a material thatis different than the material of the other tube sheet segment of thefirst pair of tube sheet segments.
 28. The tube sheet construction ofclaim 27 wherein one of the tube sheet segments of the second pair oftube sheet segments is constructed of a material that is different thanthe material of the other tube sheet segment of the second pair of tubesheet segments.
 29. The tube sheet construction of claim 18 including aninterstitial layer disposed between two adjacently disposed tube sheetsegments.
 30. The tube sheet construction of claim 29 wherein theinterstitial layer is a passive layer for the control of flow throughthe tube sheet construction.
 31. The tube sheet construction of claim 29wherein the interstitial layer is a passive layer for providing at leastone of filtration, flow control, shock absorption, magneticcharacteristics, dosing, chemical or medical treatment, or ion exchange.32. The tube sheet construction of claim 29 wherein the interstitiallayer is an active layer, in combination with a stimulus device forapplying a stimulus to the active layer.
 33. The tube sheet constructionof claim 32 wherein the stimulus device is for applying a magnetic fieldto the active layer.
 34. The tube sheet construction of claim 29 whereinthe interstitial layer is an active layer, in combination with a sensingdevice for eliciting a response from the active layer.
 35. The tubesheet construction of claim 29 wherein the interstitial layer is anactive layer for sensing one of temperature, pressure and force.
 36. Thetube sheet construction of claim 29 wherein the planar tube sheetsegments are both constructed of a non-conductive material and saidinterstitial layer is constructed of copper.
 37. The tube sheetconstruction of claim 36 wherein the non-conductive material includes aglass reinforced plastic material.
 38. The tube sheet construction ofclaim 29 wherein at least one of the planar tube sheet segments isconstructed of a non-magnetic material and the interstitial layer isconstructed of a magnetic material.
 39. The tube sheet construction ofclaim 18 wherein at least one of the planar tube sheet segments isconstructed of a material that exhibits magnetic susceptibility,including one of a ferromagnetic, a ferrimagnetic, and anantiferromagnetic material.
 40. The tube sheet construction of claim 18including an interstitial layer disposed between tube sheet segments andat least one sensor element supported by the interstitial layer.
 41. Thetube sheet construction of claim 18 wherein one of the tube sheetsegments of the first pair of tube sheet segments is in common with oneof the tube sheet segments of the second pair of tube sheet segments.42. The tube sheet construction of claim 18 wherein neither of the tubesheet segments of the first pair of tube sheet segments is the same aseither of the tube sheet segments of the second pair of tube sheetsegments.